CVI XS Controllers V 5.5.X. Operator s manual

Transcription

1 Part no Issue no 06 Date 05/07 Page / 76 CVI XS Controllers V 5.5.X Operator s manual Model Part number CVIXS Original instructions. Copyright 07, Ets Georges Renault 4488 St Herblain, FR All rights reserved. Any unauthorized use or copying of the contents or part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. Use only authorized parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability.

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3 CVI XS _06 TABLE OF CONTENTS - SAFETy INSTRuCTIONS Statement of use General instructions INTROduCTION CVI XS range Controllers CVI XS specifications Communication Tools CVIPC CVINET WEB PC Software evaluation version Description Delivered equipment Dimensions Characteristics Front panel Bottom panel INITIAL START up Installation STOP signal Switch OFF DIN rail mounting Support mounting Tool cable connection Power supply cable connection Extension box connection Fieldbus module Switch ON Start up How to enter or modify an alphanumeric field Language selection Setting the date and time Contrast adjustment Access code Activation code Control screens Results menu PROGRAMMING CYCLES and PARAMETERS menu LEARNING menu CYCLES menu Introduction Selecting the cycle Cycle general parameters Programming the phase Programming the parameters Sequence menu QUICK CYCLES menu SPINDLE menu STATION menu STATION General parameters INPUT / OUTPUT configuration INPUT menu OUTPUT menu REVERSE menu PERIPHERALS menu SERIAL PORT menu ETHERNET CONFIGURATION menu ETHERNET SOCKET menu ETHERNET SOCKET menu ETHERNET SOCKET 3 menu PLC menu REPORT OUTPUT menu BAR CODE menu CVINET menu TOOLSNET menu CONTROLLER menu CURVES menu MAINTENANCE MAINTENANCE menu TEST menu CHANNEL TEST menu COUNTERS menu CALIBRATION menu Options BRDx - controller backup SERVICE menu Maintenance operation Changing the memory battery Desoutter Tool and Account Services Spare parts /07 3 / 76

4 _ CONNECTIONS PC wiring diagram Synchronizing several controllers Example of connection diagram Tool cables ERXS cable ERXS extension cable PRINTING FORMAT FOR tightening results PC format PC3 format PC4 format Title Result PC5-A format Report per spindle: torque rate, torque, angle Reading results of spindle (x times the number of spindles) PC5-B format Report per spindle: torque, angle, torque rate Available parameters programmed for spindle (x times the number of spindles) Results of spindle (x times the number of spindles) CVI XS 0 - CyCLE FLOw CHART ANd TIMING chart Cycle flow chart Cycle timing chart Timing chart when using a crowfoot tool TROUBLE SHOOTING HELP Warning Report codes Operating problems due to adjustment problems Operating problems due to wear or breakdown GLOSSARY TIGHTENING STRATEGy Guide Torque control Torque control and angle monitoring Angle control and torque monitoring Prevailing torque control Seating detection Main phase: Seating detection Secondary phase : Post Seat Stall torque controlled tightening / 76 05/07

5 CVI XS - SAFETy INSTRuCTIONS. - Statement of use This product is intended to be used to drive, monitor and control the ERXS range tools. No other use permitted. For professional use only. EMC restriction of use: for industrial use only.. - General instructions To reduce risk of injury, everyone using, installing, repairing, maintaining, changing accessories on, or working near this tool must read and understand the safety instructions before performing any such task. Failure to follow all instructions listed below may result in electric shock, fire and/or serious personal injury. Save all warnings and instructions for future reference. General safety instructions are collected in the tool safety booklet and quick start user manual INTROduCTION. - CVI XS range The electric tightening system is automatically controlled by measuring the power consumption of the tool and monitoring the angle rotation. This technology provides a complement to the range of traditional systems fitted with a torque transducer. The electric power tool are either hand held series.. - Controllers CVI XS range is only composed on model with hardware to drive low torque tools as ERXS..3 - CVI XS specifications _06 Programming modes Quick cycle X Learning mode X Number of cycles 50 Number of phases available 5 Phase characteristics Search sequence X Approach X Run down speed X Final speed phase X Action on NOK X Run reverse X Jump to another phase X Prevailing Torque X Synchronisation phase X Tightening strategies Torque X Torque with angle monitoring X Angle with torque monitoring X Yield point Seating detection X Stall torque X 000 to 0000 Number of stored results according configuration.4 - Communication CVI XS controllers are equipped of the following communication facilities: Ethernet ports for CVIPC or network communication. RS3 port to connect barcode readers or CVIPC Logical Inputs and 8 logical Outputs..5 - Tools The complete range of tools can work with CVI XS controllers. Every tool has a memory. When connecting the tool to a controller, the controller recognizes the tool and set automatically all specific parameters. The selection of the tool takes account of the operating conditions as stated by the user, who shall not exceed the operating limits as specified by the manufacturer at the time of the selection. Any excessive internal temperature (over 00 C) of the tool electric motor is detected and stops the tool. It can start again only if the temperature decreases below 80 C. Handheld tools ERXS0 ERXS50 ERXS80 05/07 5 / 76

6 _06 CVI XS.6 - CVIPC CVINET WEB CVIPC 000 is an optional PC software package. It offers easy and user-friendly programming and real time monitoring of CVI XS controllers. CVIPC 000 can be installed on standard PCs running Windows 000, XP, Vista or 7 and communicates with CVI XS controller via Ethernet TCP/IP or RS3 port. The real time monitoring functions include access to Cpk, operator monitor, etc. CVINET WEB is intended to collect & store 00% tightening data in a real-time database with advanced analytics via a web based software in service mode..8 - PC Software evaluation version It is possible to download an evaluation version from the following web site: To access to last software up-date, select "Software" tab. No password is required. 6 / 76 05/07

7 CVI XS 3 - Description 3. - Delivered equipment Front panel _ CVI XS box Quick start manual 3 Safety manual 3. - Dimensions.3 7 Min, OK, Max Leds for the display of tightening report Display 3 Escape key to exit a screen without change 4 Validate key to exit a screen and save all changes 5 Enter key -- for an alphanumeric value -- to validate a change -- to display the next screen 6 Up / Down key -- to scroll through a menu -- to scroll through a data entry screen -- to increment digits in digital entry mode 7 Left / Right key -- to scroll through a (lozenge-tagged) list -- to scroll through a data entry field -- to enter an alphanumerical value 8 Print key 9 On/Off mains power key 0 Power supply Led Bottom panel Characteristics Weight:.kg. IP: 40. Working temperature: 0 / +45 C. Voltage: 36 VDC. Average power: 50 W. 5 7 Ethernet port RS3 port, SubD 9 points: -- PC cable ref.: Printer cable ref.: BRDx ref.: Tool connection 4 Ground connection 5 Connector for PLC or indicator box or socket tray connection, it includes the STOP signal 6 Power supply connector 7 Connector to vacuum pump 4 05/07 7 / 76

8 _ INITIAL START up 4. - Installation Before switching on, make sure that the controller is installed in accordance with the installation and safety instructions mentioned in this manual, see "Safety instructions", page STOP signal Check that the "STOP" signal is correctly connected to the Input connector of the controller. The STOP can be connected either to the PLC, or to a push-button close to the tightening station Switch OFF CVI XS OFF = 0 OR If not connected, check that the dip switch is correctly positioned. A B OFF ON Dip switch A B OFF position (External stop connected to SubD5) ON position (No external stop) The opening of the STOP contact disables the power circuit. Note that it is recommended to wire the STOP when using handheld tools, but that it is absolutely necessary for fixed tools. 8 / 76 05/07

9 CVI XS _ DIN rail mounting A Support mounting A x4 0.8 Nm ±0% x4 0.8 Nm ±0% B B x4 x4. Nm ±0%. Nm ±0% C D C x4. Nm ±0% Kit rail DIN support CVIXS ref.: DIN rail Kit angle support ref.: /07 9 / 76

10 _06 CVI XS Wall mounting Table Mounting A Ø3 x Ø6.5 x Ø6.5 x B Tool cable connection A B C XS tool cable ref.: a b c D x 9 Nm ±0% Ød D > 0 x Ø d Although our cables are designed to work under drastic conditions, we recommend that you check the following points for longer service life: Bending radii should not be lower than 0 times the cable diameter (c). Friction with the outer sheath should be restricted (b). Any direct pull on the cable should be avoided (a). 0 / 76 05/07

11 CVI XS _ Power supply cable connection Extension box connection B DIN rail mounting A 3 x4 5 / 30 VAC A 0.8 Nm ±0% XS power supply ref.: Main cable: EU US UK CH B C 4 D 5 CVIXS extension box DIN rail support rail (x) ref.: Screw (x4) ref.: DIN rail 5 CVIXS controller 05/07 / 76

12 CVI XS _ Fieldbus module Support mounting A DIN rail mounting x4 A 0.8 Nm ±0% B B C C b a CVIXS extension box CVIXS controller / 76 b fieldbus module 05/07

13 CVI XS _ Support mounting A Suitable for following fieldbus modules : Ref. Fieldbus module ETHERNET IP PROFIBUS DP PROFINET - port PROFINET - ports CC LINK DEVICENET MODBUS TCP SLAVE Switch ON B B A ON C fieldbus module 05/07 3 / 76

14 _ Start up When switched on, the controller automatically detects the correct operation of the tool and of the controller itself. If everything is OK, the control screen is displayed by the CVI XS. If a problem occurs when the controller is switched on, the screen displays: NOT READY. Press to display a second screen which provides more details about the cause of the problem How to enter or modify an alphanumeric field Language selection CVI XS Press to position the cursor under the different field (). Press or to position the cursor under the desired character (). 3 Press or to change the field (3). Press or to position the cursor under the next character. When finished, press to validate. 4 / 76 05/07

15 CVI XS _ Setting the date and time Contrast adjustment (-) (+) Press or to adjust the contrast and validate. 05/07 5 / 76

16 _06 CVI XS Access code The access code is used to protect the controller against any keying error. At the time of delivery, no code is programmed; the icon is displayed on the screen. Enter the new code. Press or to write (). Press to validate. Press or to position the cursor under the next character (). Lock access by entering your code again. The padlock icon will lock meaning that writing is prohibited. If an access code has been programmed and the operator wants to change the data stored, it is necessary to enter the code each time the controller is switched on. 8 alphanumerical characters maximum. 6 / 76 05/07

17 CVI XS _ Activation code Control screens Press to display an additional message providing information on the origin of the fault. Press or to move from one screen to another. Some controller functionalities are protected by an activation code associated to a software licence. To get the activation code corresponding to a functionality (for example the communication to a ToolsNet data base), you will need the MAC number of the controller given in the above example. After the registration procedure you will get the activation code to be completed in this screen, activating the functionality. 05/07 7 / 76

18 _06 CVI XS Screen No Results menu 3 4 Counter Status of the NcyOK counter 3 Tightening results 4 Detailed tightening report Screen No. displays the tightening results of the last run cycle (3), the detailed tightening report (4) and the status of the NcyOK counter (). Screen No. Tightening report Screen No. displays the tightening report () : OK or NOK. Screen No. 3 Status of inputs Status of outputs Provides information on the status of inputs () (left-hand column) and outputs () (right-hand column) according to tightening report. This menu allows you to display and delete the tightening results. Screen No Result of a bar code reading Screen No. 4 displays the result of a bar code reading (). 8 / 76 05/07

19 CVI XS 5 - PROGRAMMING 5. - CYCLES and PARAMETERS menu The CYCLES menu allows you to: Action Determine the best programming Change the programming of a cycle in detail Menu LEARNING CYCLES _ LEARNING menu This is a very simple and fast way and to program a cycle for non expert people. The controller adapts automatically speeds and all other parameters by analyzing the joint. Nevertheless if you are not completely satisfied it is always possible to adjust any parameters using the CYCLES menu. Quickly program a cycle Create a sequence QUICK CYCLES SEQUENCE The PARAMETERS menu allows you to: Action Display the tool features Dedicate the application Program the serial port, the report output, the bar code Program a comment, Bolt number Setup CURVES Menu SPINDLE STATION PERIPHERALS CONTROLLER CURVES Cycle Press or to select a cycle. Press to validate. 05/07 9 / 76

20 _ CYCLES menu CVI XS Max speed limit Enter max speed limit (if required). Press to validate. 3 3 Final torque Enter final torque. Press to validate Introduction The CYCLES menu allows you to change or create the programming of the cycles. A tightening cycle consists of a sequence of phases run consecutively. Each phase is defined by main parameters and tightening instructions according to the selected type of tightening and motor settings. Possible number of phases 5 Possible number of cycles 50 Various phases available in a cycle Search sequence Approach Run down speed Final speed Run reverse Act. on NOK Jump Prevail. Torque Synchr. waiting Empty phase The procedure for programming the cycle can be broken down as follows: Selecting the cycle. Selecting and sequencing the phases. Programming the parameters of each phase. Selecting an Action on NOK or not. Entering a comment. Programming the Number of cycles OK. S d D F R V J T W 4 Learning Perform 3 tightening operations. Press to validate. 0 / 76 05/07

21 CVI XS _ Selecting the cycle Cycle general parameters 4 3 Action on NOK Comment 3 Cycle parameters 4 List of the different phases to be created Cycle general parameters are composed of: Action on NOK applied to the complete cycle (). A comment of 40 characters as a maximum between Act. on NOK field and Nb cycles OK field (). Cycle parameters applied to the complete cycle (3). The list of the different phases to be created (4) (see programming the phase further in this manual) Programming the action on NOK for each cycle Associated with the cycle, this menu allows you to detect anomalies at various stages of the tightening cycle. As soon as a reject report is emitted by a phase (Approach, Final speed phase, Run Reverse, Prevailing torque) one of the 3 following actions can be performed. Normal mode Stop the cycle at this phase. Stop the cycle then run reverse a given number of rotations. Stop the cycle then run reverse the number of rotations already performed during the approach phase (if any). Cycles The list of the already programmed cycles is displayed. Press or to select a cycle (). Press to validate. This menu is used as an alternative to the insertion of an Action on NOK Phase, with the following advantages: Sequencing of a cycle (Approach, Run Down Speed, Final Speed) without inter-phase stop. No additional phase. A single programming to monitor all the stages of the tightening cycle. Except for the approach phase, this action on NOK is performed only if an inter-phase time is programmed. 05/07 / 76

22 _06 Warning: when used with hand held tools, programming an action on NOK with run reverse may be dangerous for the operator. Select the relevant action: Parameter Unused Stop cycle Run reverse N.rotat Rv speed Thread Comment The option is disabled. As soon as one of the torque or angle parameters is out of tolerances at the end of one of the phases, the cycle stops at the end of this phase. The cycle stops under the same circumstances as in the Stop Cycle option, then the tool un-tightens with the programmed number of rotations. Number of run reverse rotations performed by the tool in case of fault (0-00). The value 0 causes a run reverse action which is equal to the number of rotations performed in the approach phase if this phase has been programmed. Otherwise, the number of rotations is equal to 0. Run reverse speed associated with an action on NOK per cycle or per phase. Right / Left. When an action on NOK phase has been programmed, it will be processed as a priority with respect to the action on NOK of the cycle. CVI XS Programming cycle parameters for each cycle Nb of cycles OK Report threshold value 3 Control current strategy 4 Results strategy Select the relevant action: Parameter Nb cycles OK Rep. Thr Control I Result./ Comment Number of correct cycles to activate the NCYOK output. Torque threshold value to allow to send a cycle report. ( ) Enabled (Yes ): Torque and current are evaluated to generate cycle report. ( ) Disabled (No): Only torque is evaluated to generate cycle report. Cycle: Report is generated when cycle is completed. Phase: Report is generated any time a phase is completed. 3 4 / 76 05/07

23 CVI XS Programming the phase After selecting a cycle, the cursor will move to the line where the various phases of the selected cycle are shown. You will be allowed to modify, insert or delete a phase _ Inserting a phase Create a blank before the phase before which you want to insert a new phase: Creating (or changing) a phase Proceed as before to create a phase Deleting a phase Position the cursor on the phase that you want to delete. 05/07 3 / 76

24 _ Programming the parameters Using and, position the cursor on the phase whose parameters you want to program. Press to validate Search sequence phase This phase may be useful to insert the bolt head in the socket. It allows rotating slowly the socket in one direction or the other or alternatively to a predefined angle or time. CVI XS Parameter Comment Int.time Time programmed between this phase and the next one: 0-0 s. Nb rotat. Number of rotations: Stop time Stop time: 0-0 s. Rotat.Typ Rot.time or Rot.angl. Direction Rotation type: Time / Angle. Rotation time: s / Rotation angle: Right / Left / Alter. If the direction is alternate, half the rotations are clockwise and the other half are in the opposite direction. Speed Rotational speed: 0-00%. Accelerat Vacuum 0-40 s. Acceleration or deceleration time to switch from one speed to another, this parameter is enabled for the first phase and when the inter-phase time is not equal to zero. When the inter-phase time is equal to zero, acceleration is automatically optimized. Suitable only when Pump.Src is set to Step. ( ) Enabled (Yes): Pump is activated. ( ) Disabled (No): Pump is not activated. No result for this phase. The maximum time is simply displayed for the search sequence phase as it implicitly equals the number of rotations multiplied by the rotation time + stop time. 4 / 76 05/07

25 CVI XS _ Approach phase It allows you to quickly approach the fastener without reaching the joint. It is particularly recommended in the case of hard joints for which the approach speed should be restricted in order to control the final torque Run Down Speed Phase Parameter Int.time Nb rotat. Max T Safety T Vacuum Other... Comment Time programmed between this phase and the next one: 0-0 s. Number of rotations performed by the tool during this phase: Maximum torque that should not be reached at the end of the phase: 0 Nm to max. value of the spindle. Safety torque, stops the spindle if reached during the phase. Suitable only when Pump.Src is set to Step. ( ) Enabled (Yes): Pump is activated. ( ) Disabled (No): Pump is not activated. See Motor parameters. Parameter Comment Max.time Maximum phase running time: s. Int.time Time programmed between this phase and the next one: 0-0 s. Target T Target torque: 0 Nm to maximum value of the spindle (screw approach torque). Vacuum Suitable only when Pump.Src is set to Step. ( ) Enabled (Yes): Pump is activated. ( ) Disabled (No): Pump is not activated. Other... See Motor parameters. No result for this phase. The phase result is OK if: The torque is lower than the programmed maximum torque. AND If the programmed number of rotations has been reached. 05/07 5 / 76

26 _06 CVI XS Final Speed Phase Parameter Comment A.seat Gradient angle : Delay Angular delay : Other... See motor parameters. Detailed RP: See "Tightening strategy guide", page 6. Parameter Comment Max.time Maximum phase running time: s. Int.time Time programmed between this phase and the next one: 0-0 s. Tightening Torque. strategy Torque + Angle. Angle + Torque. Yield point. Seating. Post-seating. Min T Minimum torque: 0 Nm to maximum value of the spindle. Target T Target torque: 0 Nm to maximum value of the spindle. Max T Maximum torque: 0 Nm to maximum value of the spindle. Safety T Safety torque: Threshol Angle threshold: 0 Nm to maximum value of the spindle. Min A Minimum angle: Max A Maximum angle: Safety A Safety angle: Slp.min Min. torque rate: Slp.max Max. torque rate: Nb.sampl Number of samples: 0-3. End Slop Target torque rate: 0-00%. A.plasti Angle in plastic zone: Vacuum Suitable only when Pump.Src is set to Step. ( ) Enabled (Yes): Pump is activated. ( ) Disabled (No): Pump is not activated. T.seat Gradient torque : / 76 05/07

27 CVI XS _ Action on NOK Phase When a report is rejected (max. torque or angle reached, etc.), it is possible to apply a specific corrective action to the cycle, either by stopping the cycle or by programming a corrective phase. For example: untighten the screw, repeat tightening, etc Run reverse phase You must first choose: The fault(s) to which you want to apply a corrective action. The number of tests (from to 99). Then, you must choose corrective actions for: All attempts except the latest one. The latest one only. Various actions on NOK are available: Parameter End Rrv.+End Jump Rrv.+Jump Thread Rv time Comment To stop the tightening cycle. A Run Reverse phase is run according to the programmed time then the cycle is stopped. The cycle proceeds to the indicated phase. A run reverse phase is run according to the programmed time, then the cycle proceeds to the indicated phase. Right / Left. No phase RP. Run reverse time: 0-99 s Parameter Comment Max.time Phase running time out: s. Int.time Time programmed between this phase and the next one: 0-0 s. Strategy Torque/Torque+Angle/Angle+Torque. Min T Minimum torque: 0 Nm to maximum value of the spindle. Target T Target torque: 0 Nm to maximum value of the spindle (torque or torque + angle strategy). Max T Maximum torque: 0 Nm to maximum value of the spindle. Safety T Safety torque: 0 Nm to maximum value of the spindle. B-away T Breakaway torque: starts the torque control (strategies: torque or torque + angle), must be higher than final torque. Threshol Angle threshold: 0 Nm to maximum value of the spindle. Min A Minimum angle: 0-9,999. Target A Target angle: 0-9,999 (angle + torque strategy). Max A Maximum angle: 0-9,999. Vacuum Other... Suitable only when Pump.Src is set to Step. ( ) Enabled (Yes): Pump is activated. ( ) Disabled (No): Pump is not activated. See motor parameters. Detailed RP: See "Tightening strategy guide", page 6 (torque, torque + angle, angle + torque and prevailing torque). 05/07 7 / 76

28 _ Motor parameters CVI XS Jump to another phase This phase allows you to design more sophisticated cycles. For example: D F V F F3 J Parameter Fc(Hz) Thread Comment Bandwidth adjustment from 4 to 8Hz. Reducing this value allows you to filter the defects in the Torque signal and improve the dispersion of the torque installed (Cp or Cam), which may be useful in particular when using a Crowfoot head. Warning: as a result, the adjustment of the torque (Cpk) may be modified. It can be adjusted by calibrating the tool on the assembly ("CALIBRATION menu", page 5). Right / Left. Speed Rotational speed: 0-00%. Acceler Reset External stop Min % 0-0 s. Acceleration or deceleration time to switch from one speed to another, this parameter is enabled for the first phase and when the interphase time is not equal to zero. When the inter-phase time is equal to zero, acceleration is optimized automatically. The Reset function allows you to reset the torque and/or angle values at the beginning of the current phase. Yes/No, the following conditions must be met for the system to stop the current phase and shift to the next one: The External Stop parameter must be on Yes in this screen. The signal at the External Stop input of the Input/Output connector must shift to. Minimal motor speed allowed when reaching torque target. D Phase Run down speed F Phase Final speed V Phase 3 Action on NOK: IF NOK, jump to phase 6 (F3) ELSE run phase 4 (F), then stop the cycle F P Phase 4 Final speed Phase 5 Empty phase: the cycle is stopped F3 Phase 6 SCY phase in case of NOK on phase (V) J Phase 7 Jump to phase 4 (F) to finish No phase RP. 8 / 76 05/07

29 CVI XS Prevailling Torque Phase This phase allows you to monitor the load moment (prevailing torque) of a screw or nut. The initial time out (expressed in time or angle) allows you to eliminate the shock pulse when starting the motor and the mechanism. Parameter External stop Vacuum _06 Comment Yes / No - The following conditions must be met for the system to stop the current phase and shift to the next one: The External Stop parameter must be on Yes in this screen. The signal at the External Stop input of the Input/Output connector must shift to. Suitable only when Pump.Src is set to Step. ( ) Enabled (Yes): Pump is activated. ( ) Disabled (No): Pump is not activated. Detailed RP: See "Tightening strategy guide", page 6 (torque, torque + angle, angle + torque and prevailing torque) Synchro Waiting Phase This phase allows you to synchronize the phases of several controllers. To synchronize several controllers, you must program a waiting phase for each controller and use the Synchro signals (see "INPUT / OUTPUT configuration", page 35). Principle: Each controller reports to the others that it has reached its waiting phase by resetting to 0 the Synchro signal. Then it waits until the other controllers reach their own waiting phase by scanning the Synchro input. Parameter Comment Max.time Phase running time out: s. Int.time Time programmed between this phase and the next one: 0-0 s. Target A Target angle: 0-9,999. Min T Max T Safety T Start typ Rot.angl. or Rot.time Direction Minimum torque: 0 Nm to max. value of the spindle. Maximum torque: 0 Nm to max. value of the spindle. Safety torque: 0 Nm to max. value of the spindle. Type of start: Time / Angle. Rotation Angle or Time: 0-9,999 or 0-0 s. Direction: Right/Left. Speed Rotational speed: 0-00%. Accelerat 0-0 s. Reset: Angle Yes / No Reset: Torque Yes / No Controller n Controller n S S D D F W W F In the example, the controller no. runs the beginning of the cycle (Search Sequence, Run Down Speed), then waits until the controller no. has completed its phases (Search Sequence, Run Down Speed, Final Speed) to run together the end of the cycle. F 05/07 9 / 76

30 _06 CVI XS After a 0 s delay (max. time programmed by default), the controller continues or stops the cycle Sequence menu 3 4 No phase RP. 5 6 Sequence description Number of cycles OK 3 Cycle description 4 Cycle 4 in progress 5 Controller running in sequence mode 6 Cycle in progress / number of cycle OK in cycle 4 A sequence is a chain of cycles. The CVI XS can only comprise one sequence and this sequence can be made up to the maximum of 8 cycles. During the course of the sequence, when the active cycle is valid, the sequence advances. If not it stops on the cycle in progress. At the end of a successful sequence, the output Number of cycle OK (NCYOK) is equal to. The Reset entry allows to reset the sequence. It is possible to name the sequence by adding a comment (). 30 / 76 05/07

31 CVI XS _ QUICK CYCLES menu This menu allows you to quickly program the cycles. By default, the quick cycles consist of a run down speed and final speed phase. The operator only programs the target torque and the maximum angle on the screen. It is the controller itself which calculates the speeds and all of the other default parameters. Nevertheless if you are not completely satisfied it is possible to adjust any parameters using the CYCLES menu. 3 Cycle Final torque 3 Max angle Press or to select a cycle (). Press to validate. Enter final torque (). Press to validate. Enter max Angle (3). Press to validate. 05/07 3 / 76

32 _ SPINDLE menu This menu displays controller and tool identification and characteristics STATION menu CVI XS 3 / 76 05/07

33 CVI XS _ STATION General parameters Screen name By default Comment Name - Possibility to associate a name to the station. Mode Normal When programming a cycle, the machine mode is written into the cycle. Unit Nm Nm / Ft Lb / In Lb / kg m / kg cm / Ncm / InOzf / gf cm. Cyc.Src Keypad Keypa / PC / Bar c / I/O - Source of the cycle number: peripheral used to program the current cycle: keyboard, PC, Bar code, Inputs/Outputs (binary programming). Sel.sequence No ( ) Enabled (Yes): Sequence mode. ( ) Disabled (No): Cycle mode. Lock.NbCyOK No Lock N cycles OK: when this function is enabled, the system locks the start cycle as soon as the number of cycles run with an accept report has reached the programmed number of cycles. A reset command must be sent to unlock the cycle start. Scy pulse No Start cycle by pulses: the Start Cycle signal can be activated with a pulse. For safety purposes, this parameter is only available on fixed spindles. Warning: It is strongly advised against programming the SCY pulse option if handheld tools are used. As the tool only stops at the end of the tightening cycle, this may result in a risk of injury for the operator. Tool En None Source to enable tool: None, I/O, PLC, Protoc. Peripheral used to enable tool: -, according to input signals, according to PLC (field bus module), according to active protocol (Ethernet socket). Transducer Only No ( ) Enabled (Yes): Torque transducer tool only. ( ) Disabled (No): Current monitoring tool. Stop sp En=0 No Stop the tool when tool enable signal disappears. Requires Tool Enable to Yes Err.Ack. No Yes / No (to validate start cycle after a reject report). NOK :SCY=0 Yes Report NOK when start cycle is released. When this function is enabled (Yes), the report is NOK and the Scy message is displayed when the start cycle is released. When the function is disabled (No), the report is OK and the Scy message is displayed when the start cycle is released. 05/07 33 / 76

34 _06 CVI XS Screen name By default Comment NOK timeout Yes Report NOK when time out occurs. When this function is enabled (Yes), the report is NOK and the Time-Time message is displayed when the time-out occurs. When the function is disabled (No), the report is OK and the Time message is displayed when the time-out occurs. Push Start No When the function is disabled (No), the tool Push Start is inhibited. The tool can be started either by pressing the lever or by enabling the external start input. When the function is enabled (Yes), the tool can only be started by Push Start. Ergo-stop Yes When the function is enabled, the operator will experience less of a jerk at the end of the tightening operation. Report Ack No Yes / No (to validate start cycle after any report, OK or NOK RP durati 0.0 A value which is different from 0 allows you to program the pulse (0. to 4.0 s) reports (accept, reject, NCYOK) at end of cycle. With a value equal to 0, you can program a continuous status of the reports at end of cycle. K torque/spindl or K torque/cycle Yellow LED Blue LED Pump.Src Warning: When setting function connected to tool LEDs and controller outputs, make sure that tool yellow LED and tool blue LED are connected to functions also connected to controller outputs. This option allows you to define: Either one correction coefficient per spindle, stored in the tool memory. It is set to by default and can be changed using the manual calibration procedure, starting from the maintenance menu. This coefficient is used to calculate the torque, independently of the cycle run. Or one correction coefficient per cycle, stored in the controller memory. It is set to by default and can be changed using the manual calibration procedure for each programmed cycle. The coefficient used to calculate the torque is that associated with the current cycle. The yellow LED on the tool can be used to give the operator specific information. One of the following functions can be connected to the yellow LED: Output: Free / Ready / IN CYC / Bad report / Good report / NCY OK / CYC / CYC / CYC 4/ SYNC / CYC 8 / Torque OK / Torque NOK / Angle OK / Angle NOK / Maintenance alert / Sp.RDY. Negate: If ticked, the meaning of the output signal is inverted to the usual meaning. Blink: If ticked, the output signal blinks when activated. The blue LED on the tool can be used to give the operator specific information. One of the following functions can be connected to the blue LED: Output: Free / Ready / IN CYC / Bad report / Good report / NCY OK / CYC / CYC / CYC 4/ SYNC / CYC 8 / Torque OK / Torque NOK / Angle OK / Angle NOK / Maintenance alert / Sp.RDY. Negate: If ticked, the meaning of the output signal is inverted to the usual meaning. Blink: If ticked, the output signal blinks when activated. None / SCY / Step / I/O - Source of pump command. Peripheral used to activate the pump: when cycle is started, according to setup for each cycle step, acccording to input signals. 34 / 76 05/07

35 CVI XS INPUT / OUTPUT configuration I/O connector The STATION menu also allows you to reconfigure the addresses of the input and output functions on the I/O connector. According to the desired operation, you can use either the default configuration, or the dedicated configuration with functions not defined in the default configuration. All functions can be configured on any input or output available. You can configure the same output function on several outputs of the I/O connector _06 Note that there are separate common circuits on OUTPUT: COM common for output to 4. COM common for output 5 to 8. It is possible to connect COM and COM together to get a unique common circuit for all outputs Vacuum pump connector E A B SubD 5 A C D B GND GND +4V +4V CYC CYC CYC4 VALSP ACKNOW SCY DIR RESET 0VE STOP COM I. I. I.3 I.4 I.5 I.6 I.7 I.8 GND VE STOP COM I. I. I.3 I.4 I.5 I.6 I.7 I.8 GND A Connector 3 pins - Male B Connector 3 pins - Male C White (0.34mm²) D Brown (0.34mm²) E Twisted pair 360 ground shielded cable Current delivered by +4V is limited to 500mA max, including digital inputs, digital outputs and vacuum pump. This connector is wired with only following signals: -- - Pump +4VDC -- - Pump GND +4V 0VE COM V 0VE COM Note that pump is driven according to output function attached to output O.8. CYC O. 8 O. 8 CYC O. 9 O. 9 CYC4 O.3 0 O.3 0 READY O.4 O.4 INCYC O.5 O.5 ACCRP O.6 3 O.6 3 REJRP O.7 4 O.7 4 NCYOK O.8 5 O.8 5 Manufacturing configuration Note your customized configuration 05/07 35 / 76

36 _06 CVI XS INPUT menu Inputs Name Factory config. Comments Cycle selection CYC X Binary coding - weight, i.e. from 0 to. Cycle selection CYC X Binary coding - weight, i.e. from 0 to 3. Cycle 4 selection CYC4 X Binary coding - weight 4, i.e. from 0 to 7. Cycle 8 selection CYC8 X Binary coding - weight 8, i.e. from 0 to 5. Cycle 6 selection CYC6 Binary coding - weight 6, i.e. from 0 to 3. Spindle validation VALSP X Validates - or not - the tool start in both tightening directions if "Sp. val." is enabled in the Station Menu. Tightening direction validation Run reverse direction validation Error acknowledgement VSPTIG VSPLOO Validates - or not - the tool start in the tightening direction if SpV.rrv is enabled in the Station Menu. Validates - or not - the tool start in the run reverse direction if "SpV.rrv" is enabled in the Station Menu. ACKNOW X Validates again the tool operation after a reject report if the error acknowledgement function in the Station Menu is enabled. Start cycle SCY X The cycle is run as long as the signal is at. When the signal drops, the cycle stops and the report is sent to the PLC. Tightening / Run reverse DIR X Validates the un-tightening direction as soon as the Start Cycle signal appears, at the speed programmed in the Station Menu and with the maximum current of the tool. Reset RESET X This signal resets the tightening reports and deletes the results displayed. Running sequence is aborted. External stop EXSTOP When the parameter is programmed on Yes in the programming screen of the run down speed, final speed and run reverse phases, the system stops the current phase on a pulse and switches to the next one. Synchronization SYNC Validates the synchronization of the tightening phases of several controllers (see "Synchronizing several controllers", page 54). Pass through P.THRU When this value is set, I/O are devoted to PLC. They are no longer read by the controller. Reset Cycle RSTCY This signal resets tightening report for last cycle in running sequence. Running sequence is not aborted. 36 / 76 05/07

37 CVI XS _06 Inputs Name Factory config. Comments Activate Pump S.PUMP When Pump.Src is set to I/O, pump is activated as long as the signal is at. Acknowledge Report RPACK Validates again the tool operation after a report if the report Ack function is enabled in the station menu PLC output, CVI XS input wiring Two configurations are available. The CVI XS 4V is used as the Common of a PLC relay board. 5.6kΩ +4V.7kΩ GND 0VE Controller input PLC output By default, the PLC 4V is sent to the inputs of the controller. +4V PLC 5.6kΩ.7kΩ 0VE 0V Controller input PLC output The inputs are type II as per standard CEI 3- (4 V / 3 ma per input). 05/07 37 / 76

38 _06 CVI XS OUTPUT menu Outputs Cycle acknowledgement Cycle acknowledgement Cycle 4 acknowledgement Cycle 8 acknowledgement Cycle 6 acknowledgement Name Factory config. Comments CYC X Binary coding -weight. The cycle acknowledgement is sent back only if it corresponds to a programmed cycle; otherwise it is at "0". CYC X Binary coding -weight. The cycle acknowledgement is sent back only if it corresponds to a programmed cycle; otherwise it is at "0". CYC4 X Binary coding -weight 4. The cycle acknowledgement is sent back only if it corresponds to a programmed cycle; otherwise it is at "0". CYC8 X Binary coding -weight 8. The cycle acknowledgement is sent back only if it corresponds to a programmed cycle; otherwise it is at "0". CYC6 Binary coding -weight 6. The cycle acknowledgement is sent back only if it corresponds to a programmed cycle; otherwise it is at "0". Ready READY X This signal is at "" when the controller is in working order. In cycle INCYC X Response to the Start Cycle request. Drops to "0" at end of cycle. Global report OK ACCRP X Sent to the PLC when the cycle is over and the global report is OK. Global report NOK REJRP X Sent to the PLC when the cycle is over and the global report is NOK. Number of cycles OK NCYOK X This signal switches to "" when the number of cycles run with an Accept report is equal to the programmed number of cycles OK. For a sequence: at the end of a successful sequence, the output "Number of cycle OK" =. Synchronization SYNC The synchronization signal falls down at the end of the phase and is used, connected with synchronization of other controllers to synchronize the next phase (see "Synchronizing several controllers", page 54). Torque report OK TRQOK Sent to the PLC when the cycle is over and the torque report is OK. Torque report NOK TRQNOK Sent to the PLC when the cycle is over and the torque report is NOK. Angle report OK ANGOK Sent to the PLC when the cycle is over and the angle report is OK. Angle report NOK ANGNOK Sent to the PLC when the cycle is over and the angle report is NOK. Maintenance alert MAINT This output allow to program maintenance alert on tool. Two types of maintenance alert are possible: counter on tool or date. Pass through P.THRU When this value is set, I/O are devoted to PLC. They are no longer read by the controller. 38 / 76 05/07

39 CVI XS _06 Outputs Name Factory config. Comments Spindle ready Sp.RDY This signal is at when the tool is in working order. Run Reverse Enabled REVERS This signal switches to when reverse mode is selected. Otherwise it is at 0 Sequence OK SEQOK This signal switches to at the end of a successful sequence. Otherwise it is at 0 Pump ON PUMPON The signal is at when pump is activated CVI XS output, PLC input wiring Below are shown the two wiring configurations available for the relayed outputs of the CVI XS. The PLC 4V is connected to the CVI XS output common. The PLC input do not receive external 4V. 3 +4V Pump connector wiring and management In order to drive vaccum pump connected to vacuum pump connector: Pump.src parameter (see 5.7.) must be setup as needed. PUMPON signal must be attached to output O8 (see 5.7.4). S.PUMP signal must be attached to an input if needed (see 5.7.3). Vacuum parameter must be setup as needed for each step (see 5.3.5). 0V Controller output PLC input 3 Common of the output relays By default, the PLC 4V is sent to the inputs of the controller. +4V 3 GND 0V Controller output PLC input 3 Common of the output relays All outputs are enabled at and relayed in the controller with a common point (4) for all outputs. Features of the contacts: A / 30V / 30W max. DC on resistive charge. 05/07 39 / 76

40 _06 CVI XS REVERSE menu Screen name By default Comments Rv speed 50% This speed is used at each run reverse command by the operator (the run reverse speeds used during the cycle may be programmed in the run reverse phases or in the actions on NOK per cycle). Tool En. Rev. No Yes / No Enable or disable the operator to perform a loosening operation. When No, the operator is allowed to perform loosening operation. When yes, the operator can t perform loosening operation unless the SPVALRV (spindle reverse validation) input is activated. Rev. Dir None Right : when tool selector set to right direction, reverse mode is validated and specific action is applied. Left : when tool selector set to left direction, reverse mode is validated and specific action is applied. None : reverse mode disabled. Type SpindleDir SpindleDir : Reverse in opposite of the spindle way with default parameters. Last Phase : Reverse in opposite of the last tightening phase programmed in the current cycle. Use Cycle : Use a cycle programmed in the cycles list. Number Cycle programmed with "Use Cycle" option. 40 / 76 05/07

41 CVI XS PERIPHERALS menu _ ETHERNET CONFIGURATION menu SERIAL PORT menu The serial port is used for the following functions: PC transfer (used to communicate with CVIPC 000 software). Bar code and report output. Printing the results in order of occurrence (ASCII, use Bar code and report output selection). Automatic calibration with the DELTA measuring unit (no programming is required). Parameter IP Address Mask Gateway Ping IP Nb ping startup Comment IP address of the controller in the network. In case of integrating the controller in an existing network, please contact your administrator to get the correct mask. To be set when the network uses Gateway. IP address of another equipment connected to the controller. Starting the controller, execute several pings at the corresponding address. 05/07 4 / 76

42 _06 CVI XS ETHERNET SOCKET menu ETHERNET SOCKET 3 menu The ethernet socket 3 is used for the following functions: Open Protocol (this choice needs to get a license). Desoutter Protocol (this choice needs to get a license). The ethernet socket is used for the following function: PC transfer (used to communicate with CVIPC 000 software) ETHERNET SOCKET menu PLC menu To get the functionalities it is necessary to insert an optional field bus module. The layout the setting screens shall differ according to the inserted module Ethernet/IP module The ethernet socket is used for the following functions: CVINET data collector. ToolsNet data collector (this choice needs to get a license). Parameter IP Address Mask Gateway Comment IP address of the controller in the PLC network (must differ from Ethernet address see "ETHERNET CONFIGURATION menu", page 4). In case of integrating the controller in an existing network, please contact your administrator to get the correct mask. To be set when the PLC network uses Gateway. 4 / 76 05/07

43 CVI XS _ Profinet IO module DeviceNet module Parameter IP Address Mask Gateway Comment IP address of the controller in the PLC network (must differ from Ethernet address see "ETHERNET CONFIGURATION menu", page 4). In case of integrating the controller in an existing network, please contact your administrator to get the correct mask. To be set when the PLC network uses Gateway. Parameter Slave # CC-Link Comment Slave number of the controller in the PLC network Profibus module Parameter Slave # Comment Slave number of the controller in the PLC network. Parameter Slave # Comment Slave number of the controller in the PLC network 05/07 43 / 76

44 _06 CVI XS REPORT OUTPUT menu BAR CODE menu The report is printed according to the following parameters: Format: PC / PC3 / PC4 / Specific / PC5A / PC5B / PC5C. Upon request at end of cycle (See "Printing format for tightening results", page 57). The bar code reader allows you to automatically select one of the cycles previously programmed in the controller. To enable the barcode reader, you need to do the following: Declare the source of selection of the cycles as being the bar code. Configure the serial link: Barcode function 9,600 bauds 8 data bits stop bit No parity They cannot be programmed by the PC. Set up the table of selection of the cycles according to the barcode numbers, which can be done only with the CVIPC000 software. As the barcode is read by the controller, it can perform one of the following actions: Parameter No action Reset Reset on NCYCOK Comment No action is performed. Reading the code leads to an action which is identical to the Reset action. Reading the code leads to a Reset when the programmed number of cycles OK is reached. 44 / 76 05/07

45 CVI XS _ CVINET menu TOOLSNET menu The CVINET software can be used to recover the tightening results and the curves on PC via Ethernet. This screen is the configuration of the CVINET data collector. Parameter Comment FIFO blocking When the result memory to be transmitted is full, the start cycle that follows can be locked or not (the start cycle is not locked on, but next results are not saved). Alarm thresh. When the memory filling rate reaches this value ( to 99%), an alarm is displayed. Results Tightening results. OK curves NOK curves Date synchro FIFO capacity FIFO used Connection status Tightening curves with tightening report = accept. Tightening curves with tightening report = reject. Choose how to update the machine on time (CVIPC / CVINET / CVIPC and CVINET). Memory space allocated for not transmitted results. Memory space used in the FIFO. NOK: not connected to the CVINET server. OK: connection established. The ToolsNet software can be used to recover the tightening results and the curves on PC via Ethernet. This screen is the configuration of the ToolsNet data collector. Parameter Comment System type Type of system for ToolsNet server (3 is the default: OP Undefined controller) System Identification of the system in the number controller network (group of stations) Station Identification of the station in the number controller network (individual station) FIFO blocking When the result memory to be transmitted is full, the start cycle that follows can be locked or not (the start cycle is not locked on, but next results are not saved). Alarm thresh. When the memory filling rate reaches this value ( to 99%), an alarm is displayed. Date synchro Check the box to synchronize the controller date with the ToolsNet server. FIFO capacity Memory space allocated for not transmitted results FIFO used Memory space used in the FIFO Connection stat. NOK: not connected to the CVINET server. OK: connection established. 05/07 45 / 76

46 _ CONTROLLER menu CVI XS Parameter Comment Fst Ergo-stop K.nload K.gear K.torsion Reverse Comments Possibility to add a comment up to 5 characters to identify the controller. Possibility to add a comment or figures up to 3 characters to identify the fastener. Activates or not the ergo-stop function at the end of the tightening operation. This reduces the reaction shocks at the end of the tightening and is recommended for portable tools. Nominal load coefficient for use of external torque multiplier. Update torque calibration. Gear ratio coefficient for use of an external torque multiplier. Update angle calibration. Torsion coefficient used in control angle strategies to compensate the mechanical torsion of the installation. Modify the reverse mode: Altern: each pressure on the reverse button changes the direction of rotation of the tool. shot: a pressure on the reverse button activates the loosening and return automatically to normal direction at the next start. shot: pressure on the reverse button activates the reverse mode. Start: a pressure on the reverse button starts the tool in the loosening direction as long as the reverse button is activated. 46 / 76 05/07

47 CVI XS _ CURVES menu Parameter Durat Thresh Results OK Curves NOK Curves Comments Recording time. Threshold = 0 : the curve is displayed back from motor stop for the recording time Threshold > 0 : the curve is displayed back from the defined torque threshold and for the recording time. Total number of curves stored into controller memory. Tightening curves with tightening report = accept. Tightening curves with tightening report = reject. 05/07 47 / 76

48 _ MAINTENANCE This section helps the maintenance operator to: Check that the controller + tool assembly operates correctly. Know the number of cycles run. Tune the system manually or automatically. Adjust the contrast of the display, update controller date, select the language and program an access code. Change the memory battery. Backup and restore the controller MAINTENANCE menu TEST menu START SPINDLE menu CVI XS The START SPINDLE menu allows you to check the correct operation of the tool. Select the speed and rotation direction ("Directi" reverser for a hand held tool or in the menu for a fixed tool) then press the trigger for a hand held tool. Select Reset to reset the display. Select Ventil. to start the fan and check its working order INPUT / OUTPUT menu 3 4 Input no Input no 8 3 Output no 4 Output no 8 The INPUT/OUTPUT menu allows you to check the status of inputs and to test the outputs. Testing the outputs: The cursor blinks on output (3). Press to move the cursor. Press to validate the box or not. The selected output is or is not enabled. Then it is possible to check the efficiency of the status change of this output on the corresponding input, for example on the PLC. 48 / 76 05/07

49 CVI XS _ LEDS TEST menu Tool memory check This menu allows for testing the LEDs located on the front side of the CVI XS and for testing the LEDs on the tool Servo drive check CHANNEL TEST menu Transducer check 3 Tool memory check Servo drive check 3 Tool transducer check If an error arises, a message is displayed. Press to display an additional error message. 05/07 49 / 76

50 _06 CVI XS COUNTERS menu Maintenance info screen Maintenance is configured but is not yet reached (MAINT OFF). Maintenance is configured and reached (MAINT ON (time)). 3 Controller counter Spindle counter 3 SP. Maintenance counter This menu allows the maintenance technician to know the number of cycles run. Reset counter The Controller counter shows the number of cycles run since delivery. The Tot. (total) and Par. (partial) counters show the number of cycles run by the tool. Select Reset to reset the partial counter of the tool. 50 / 76 05/07

51 CVI XS CALIBRATION menu _ Calibration service For full certified calibration, to cover your quality systems needs please consult your local Desoutter Customer Service Center that are fully prepared to support you, either at your site or in one of our workshops. Being the equipment manufacture we are prepared not only to provide the calibration service and certification, but also to adjust your equipment for its fullest performance. Our labs can provide you with either a local traceability chain to National standards or a International level, through ISO 705 certified labs Options Contact your Desoutter representative for support BRDx - controller backup The minimum software version of the controller must be: V 5..A9. The calibration procedure is recommended to compensate for any possible drift of the tool torque or after each change of tool element SPINDLE MANU menu Use this device to clone a controller. Both configuration and firmware are copied during the process. Before restoring, check that the target controller is not connected to the same Ethernet network as the source controller as this may cause a conflict between IP addresses. Connect the BRDx to the serial port of the controller as described in the user manual Go to the Maintenance menu and select BRDx. This menu is used to calculate and to apply a torque correction coefficient to the torque value of the selected cycle. The torque transducer inserted in line with the tool can be connected to any measuring unit in the Desoutter range. Run a tightening cycle 5 times and manually enter the values read on the standard instrument. The Reset value key resets the readings. The Reset coeff. key displays coefficient by default. Depending on the option selected (K Torque/spindle or K Torque/cycle) in the "STATION menu", page 3, the Torque correction coefficient is saved: Either in the tool memory. Or in the controller. The torque and angle reports MUST be correct to allow the procedure to be processed in normal conditions. 05/07 5 / 76

52 _06 CVI XS Backup 6. - SERVICE menu See "Start up", page Maintenance operation Changing the memory battery The memory battery allows you to save the parameters and results in of mains power failure. A maximum lifetime of 0 years is indicated in the manufacturer s specifications. For safety purposes, it is recommended to change the battery every 5 years Restore Prior to any battery change, it is recommended to save the tightening program as well as the results, using the CVIPC000 software. CPU board Battery ATTENTION This procedure requires that the controller be disassembled and handled by certified technicians. It also means that they should not be performed during warranty coverage or service contracts coverage, since it would void them. Please consult your local Desoutter Customer Service Center, which have fully capable and trained engineers to perform any of your service needs in relation to the tightening system. 5 / 76 05/07